CN1232421A - 塑料模制件和结构构件 - Google Patents

塑料模制件和结构构件 Download PDF

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Publication number
CN1232421A
CN1232421A CN97198620A CN97198620A CN1232421A CN 1232421 A CN1232421 A CN 1232421A CN 97198620 A CN97198620 A CN 97198620A CN 97198620 A CN97198620 A CN 97198620A CN 1232421 A CN1232421 A CN 1232421A
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China
Prior art keywords
structural member
polymeric material
moulded parts
supporting construction
mentioned arbitrary
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CN97198620A
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English (en)
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CN1093031C (zh
Inventor
I·托姆卡
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REGIONAL COMPACT CAR AG
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REGIONAL COMPACT CAR AG
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    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D29/00—Superstructures, understructures, or sub-units thereof, characterised by the material thereof
    • B62D29/04—Superstructures, understructures, or sub-units thereof, characterised by the material thereof predominantly of synthetic material
    • B62D29/041—Understructures
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14631—Coating reinforcements
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    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/16—Making multilayered or multicoloured articles
    • B29C45/1671—Making multilayered or multicoloured articles with an insert
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Abstract

塑料模制件和结构构件具有支撑结构(3),它部分或完全被构成模制件的聚合物材料(8)围住。其中支撑结构(3)由多个相互连接的高强度连续纤维加强的结构件(5)构成,从而可以按简单和廉价的方法制成不同造型的结构,如容器油箱、汽车驾驶室等等。

Description

塑料模制件和结构构件
本发明涉及一种按照权利要求1前序部分所述的塑料模制件和结构构件，如容器、壳体、储气罐、储液罐、管道、汽车驾驶室、小室、车身等等，以及制造这种塑料模制件和结构构件的方法，用于用模制件制造汽车车身、输送容器、缆车小室、燃料箱等等，上述的模制件同时构成支撑载荷的结构。
制造壳体、燃料箱等等一般大多数采用金属材料，如金属板、钢结构等等。但是，由于重量重、易腐蚀、制造方法较贵以及加工麻烦而越来越多地试图选择轻的加工简单的材料如塑料或普通的聚合物或者说塑料加工。
因此，例如对于容器、燃料塑料箱、管道、汽车驾驶室等等采用所谓的缠绕法，例如用液态树脂浸渍的所谓的粗纱、玻璃或塑料纤维线、织物带等等围绕核心缠绕成一定形状，并硬化。一方面这种造型受到很大的限制，另一方面这样制成的模制件几乎无需后加工。也没有光滑的表面，为了获得足够的强度，必须选择相对大的壁厚。
按照另一已知的方法，在大的注塑模具中松动地放入连续的加强纤维、纺织纤维织物如纤维垫、板条以及纤维半成品和织物，从而只能达到有限的支撑作用。或者在待加工的热塑性塑料中通过加入短纤维而实现整体的纤维加强。这一制造方法很复杂和昂贵并且只能生产短纤维加强的塑料，此外所制造的加工构件没有所需的强度。
按照另一种方案，借助于纤维加强的热固性塑料用深拉法在所需的模具中制造垫或板条，对此例如在压模中或通过回火实现最终的硬化。而然，这只容许很有限的造型和有限的支撑作用。这一构件也没有可以接受的表面光洁度，此外，通常硬化时反应时间太长。
因此，本发明的任务在于，克服已知方法中的缺点，并提出一种塑料模制件和支撑结构以及一种制造方法，这种模制件和支撑结构可以在采用尽可能轻的聚合物材料时按照简单和廉价的方式和方法来制造，并可实现支撑载荷的功能。
按照本发明，所提出的任务是借助于按照权利要求1的塑料模制件和结构构件以及按照权利要求16的方法完成的。
塑料结构件和构件结构由各高强度的纤维加强的简单的结构件组成，这些结构件组装成支撑结构而相互连接在一起，支撑结构中的至少一部分被构成模制件的聚合物材料围住。从而，可以按简单的方法由相对廉价的物件来生产任意形状的结构件和结构构件，其中所需的造型和表面可以按简单的方法通过聚合物的浇注或注塑来获得。从而还获得了短的节拍时间。对支撑结构用聚合物的围注获得了一种受保护的光滑的表面。例如对于大型的空间格子结构也可以只在部分范围，首先在结构件的连接点用聚合物材料围注。
从属权利要求涉及本发明有关材料、材料的组合、具有特别有利性能的支撑结构和模制件的构造的改进。
适宜于作为构成支撑结构的结构件的加强纤维尤其是由玻璃纤维、碳纤维、聚丙烯、聚乙烯、芳族聚酰胺或其他的高强度的聚合物纤维制成的连续的纤维加强。作为加强纤维的基体最好是热塑性塑料如聚酰胺(PA)、聚丙烯(PP)、聚乙烯对苯二酸盐(PET)、聚丁烯对苯二酸盐(PBT)、聚碳酸酯(PC)、聚酰亚胺(PI)、聚丙烯酸酯、聚苯硫烯(PPS)和聚醚醚酮(PEEK)。
此外，至少部分也可用热固性材料，如聚亚胺酯(PUR)、不饱和的聚酯树脂、环氧树脂、酚醛树脂、氨基塑料和必要时的酚醛清漆树脂。
这些构成支撑结构的结构件例如是造型结构如杆、管、纵向型材如T-型材、L-角板以及表面结构如板条、垫、蜂窝、格子等等。这些结构件一般可以借助于塑料技术中已知的方法来生产，最好是借助于拉拔、挤压、连铸、冲挤、压制。最好由连续的材料通过切割、后加工和裁剪而制成这些结构件。
为了制造支撑结构，这些单个的结构件通过插接、拧紧、粘接、焊接等相互连接，其中在连接区设置相应的连接件。
各结构件可以是多层的，具有至少一个高强度的核心和一个外层，此外层最好与直接围住结构件的聚合物材料兼容，或者该最外层最好粘接在直接围住结构件的聚合物材料上，或者与其良好连接或混合。结构件和热塑性聚合物材料之间的良好的粘附是通过兼容的聚合物材料实现的，该聚合物材料相互扩散，由此而形成分子连接，或通过化学结合而形成分子连接。
按照一个有利的实施例，各结构件的最外层或其表面至少几乎与直接围住结构件的聚合物材料相同，其中也可以采用聚合物板。
构成模制件和结构构件的聚合物材料至少部分包括一种热塑性聚合物，如聚酰胺、聚丙烯、聚乙烯对苯二酸盐、聚丁烯对苯二酸盐、聚碳酸酯、聚酰胺、聚苯硫烯和聚醚醚酮。原则上应尽可能使用相同的聚合物，如用于热塑性基体和结构件的涂层。其中，聚合物材料可设计成多层的，具有从结构件至模制件或结构构件的表面的减小的刚度和强度。其中，也可以将聚合物材料至少部分地发泡或着色。
从结构件至聚合物材料的外表面减小的刚度和强度是重要的，以便在出现模制件和结构构件损坏或出现变形时保证尽可能地吸收能量。尤其在制造汽车驾驶室、汽车车身、小室等等时，重要的是构成车身的模制件和结构件在所谓的碰撞试验中要尽可能大地吸收能量，以便能够尽可能给汽车或小室中的人员予以保护。
下面借助于附图所示的实施例进一步说明本发明。其中：
图1采用不同的材料的应力/应变图；
图2,2a作为本发明的塑料模制件和结构构件的例子的储液罐；
图3a-c支撑结构的连接件和连接区的例子；
图4具有箱式支撑结构的容器；
图5一种例如作为圆形桶的圆柱型支撑结构；
图6一种缆车小室；
图7一种具有部分车身的汽车驾驶室。
图1中的应力/应变图用来表示上述的事实情况。曲线K1表示例如用连续纤维加强的基体材料例如用50％的碳纤维加强的环氧树脂的结构件的高强度和高刚度的材料的应力/应变曲线S(D)。曲线K2表示用短纤维加强的热塑性材料的应力/应变曲线S(D)。曲线K3表示未加强的热塑性材料的应力/应变曲线S(D)，而K4则表示例如聚碳酸脂泡沫的所谓的泡沫结构材料的应力/应变图。
各材料至断裂的能量的吸收用曲线下方阴影线表示的面积来表示。重要的是，使各曲线下方的面积尽可能的大。这在从各结构件的核心(例如曲线K1)至模制件的表面(例如曲线K3,K4)选择成尽可能分阶段的应力/应变曲线即可实现。换言之，如果从各结构件的核心至模制件的表面所选择的材料的刚度不断减少，是有利的。当然，重要的还有，各所选择的材料要相互兼容，从而在吸收能量时在界面上不会出现分离或断裂。
对于制造模制件或结构构件来说，首先要制造各结构件。其中，例如要从管、棒、型材等等的拉拔或挤压开始，这些材料然后被切割成所需的长度。热塑性连续纤维加强的结构件例如通过拉拔制成。在挤压中例如挤压连续纤维加强的热固性塑料材料，这一材料通过相应的附加剂被迅速硬化或通过随后的处理例如回火、紫外线处理等等来硬化。上述材料也可以通过共同挤压来制成，其中，如上所述，结构件被设计成多层的。例如，内部核心可以由纤维加强的热固性塑料材料制成，而最外层至少部分由一种热塑性材料制成，例如由聚丙烯、聚碳酸酯等等制成。当然，重要的是，各材料层要相互良好粘附或兼容。
良好的粘附可以通过在边界层或边界表面的粘附或通过在边界层两侧两部分上分子的扩散来实现。而后者例如可以通过在表面上的热固性塑料尚没有完全硬化或在表面上设置可熔性热塑性塑料来实现。良好的粘附也可以通过在边界层在两部分构成边界层的聚合物之间或在聚合物的分子之间的化学反应来实现。最后也可以在两种聚合物之间设置一种有粘附力的连接层(9在图3中)。
在制成各结构件如杆、板、管、T型管等等之后将这些结构件组合成支撑结构。这例如可以通过借助于连接件的相互插接来实现，这些连接件可以具有插接部分、螺纹部分、卡接部分等等。这些连接件可以被设计成刚性的或铰接的，这样所形成的支撑结构是刚性的或是有一定的活动性。这种连接也可以直接进行，其方法是将各结构件相互粘接、焊接、螺纹连接等等。在每种情况中重要的是将支撑结构的结构件的一部分相互连接在一起。
在制成支撑结构之后将其插入压铸模或铸模中，在其上最好注塑或浇铸热塑性的聚合物材料。其中重要的是待注塑的或浇铸的聚合物熔液是与支撑结构的结构件的最外层兼容的，或者支撑结构的表面能与聚合物熔液良好连接。由于现在可以将形成模制件或结构构件的聚合物材料再次设计成多层，因此，可以在注塑或浇铸的聚合物材料硬化后将尚没有外壳的支撑结构放入另一注塑模或浇铸模中，或者将目前的注塑模或浇铸模的容积通过在壁上设置滑板扩大。这里指的是所谓的多重工具，这种工具容许注塑或浇铸多种聚合物材料以形成多层模制件。
按照这样的方法和方式可以实现从内向外刚度的上述变化，其中在外面可以注塑聚合物材料例如聚乙烯-聚丙烯共聚物，聚酯如PBT或Topas(聚合的环状乙烯基单体)，其具有相对较小的刚度，为此有良好的表面光洁度，从而不需要对最终制成的模制件或结构构件进行后加工。这样也可以给最外层着色，从而可以省去对最终制成的模制件或结构构件的油漆。
为了获得尽可能轻的模制件或结构构件，有利的是使聚合物材料至少部分发泡。适宜的是所谓例如由聚碳酸酯、聚氨基甲酸酯或聚酯如PBT或Topas，它们具有显著的重量、强度和硬度性能，也就是说，它们在轻的重量时具有相对高的表面强度。
在采用按照本发明的聚合物材料时的重大的优点在于，如上所述，不需要对制成的模制件或结构构件的表面进行后加工。也可以例如通过对聚合物的着色获得特殊的表面效果，从而省去了油漆。也可以模仿所谓的“无丙烯酰基的接触”，或者在注塑或浇铸时形成表面结构。
但是，以后也会带来另一些显著的优点，因为这样制成的模制件如车身不会生锈或腐蚀。所出现的划痕几乎看不见，也不会使车身生锈。划痕可以以后磨平，从而不再可见。
另一优点在于，这类模制件如壳体、箱体、车身等等容易重复使用，其方法是将聚合物通过溶化再制成颗粒，而纤维加强的结构件例如可以作为纤维加强件来重新使用。
本发明的构思在于，首先由所述的构件制成桁架或支撑结构，或者桁架的各结构件用简单和便宜的方式和方法制成，其中例如借助于机器人组装这些结构件。
与已知的普通的用敷设垫的整体纤维加强或上述的缠绕法不同，按照本发明可以按简单的方式和方法将结构件组装成作为桁架的支撑结构，这一桁架保证了最终模制件的明显较高的强度和形状稳定性。当然，按照本发明也可以使用平面结构件如垫或蜂窝状结构，但是，重要的是垫或蜂窝状结构要相互连接并与结构件连接。
图2表示作为本发明的塑料模制件和结构构件的例子的一种储液罐11，其中，壁透视表示，从而能看见支撑结构3。这一支撑结构3由带对角线杆17以及纵向杆19和作为结构件5用来加强各壁的横杆21的空间格子框架13组成。在储液罐11的每一角23，各结构件或杆例如借助于作为连接件7的插接连接部分25，如图3a所示相互连接在一起。其中，纵向杆17、19例如是用碳纤维加强的聚氨酯树脂杆，其经过表面处理，以便保证围住各杆的聚合物材料的良好的粘附性。这些结构件3也可以具有其他的形状，例如设计为管。然后，借助于所述的聚合物材料8用注塑填满中间空间24和26，作为杆之间的壁。
图3a-3c表示不同类型的纵向杆结构件5.1和平面结构件5.2的连接、连接件7和连接部位6，它们通过适当的选择和组装形成支撑结构3。
图3a表示作为连接件7的插接连接件25，图2中的杆17、19、21用插接连接件25通过插接或连接相互连接起来。
图3b以俯视图表示两个交叉的纵向型材例如作为结构件5的直角管的连接。结构件5粘接在作为平面连接件的板上，其中整体用部分模制件的一种纤维加强的聚合物8围住并固定。上述模制件这里构成连接区6。
图3c以横截面表示作为纵向结构件5.1的方形管的连接。上述结构件粘接或焊接在板上。然后，连接一壁部，该壁部例如由具有部分发泡区的聚合物材料8制成，或者该壁部也可以包括另一格子或蜂窝的平面结构件5.2。这一围起来的形成形状的聚合物材料8在这里形成加强的连接区6。其中，该聚合物材料也可以由两个或多个层8.1,8.2组成。为此，连接层9形成结构件和结构件5.1和5.2上的例如最外层上的聚合物材料的很强的连接。外部浇注的聚合物材料例如由纤维加强层8.1组成，接着在其上再浇注另一层未经加强的层8.2。其中，其应力/应变性能相应于图1中的曲线：8.1=K2,8.2=K3，以及发泡聚合物8.0=K4。
容器的壁例如可以用板条状即平的结构件支撑来加强，这例如表示在图4的箱型容器中。重要的是构成支撑结构的各结构件例如可以用拉拔或挤压由连续纤维加强的热塑性材料或热固性材料“连续”生产。对于具有特别高强度、刚度和很高模量的结构件的情况可以使用特别高组分的连续纤维加强，例如50-60体积百分比的连续纤维加强。至少部分使用所谓的酚醛清漆也是有利的，它比市售的热固性塑料产生更高的交联密度。
在连续纤维加强中是指所有的上述纤维，其中这些纤维在被加工入基体聚合物之前必须被亚结构化，从而其表面可以用包含这种纤维的聚合物良好润湿。当然，这也是已知的技术，因为热塑性塑料和热固性塑料用例如玻璃纤维、碳纤维、芳族聚酰胺纤维等等来加强在现有技术中是已知的。
最后也可以除了加强件外为各壁设置了在中间空间24、26中的蜂窝结构，重要的是这些蜂窝结构与其他的结构件17、19、21(图2)相连接。
这类支撑结构3的另一例子表示在图5中，具有作为连接件5的弯曲的、纵向型材和连接件7、25，这些连接件用于形成具有很大直径的管或压力罐的桶壁或管壁。
图6表示一种缆车小室31，其支撑载荷的基础桁架由本发明上述的支撑结构3构成。其中尤其对底和固定有支撑臂32的顶结构的强度提出了很高的要求，所以例如在顶33上设置作为加强件35的连接件，不同于例如侧壁中的加强件其是实心的。因此，也可以作为在侧壁中的加强件使用相对较轻的格子状结构37，而不是另一例子中的平面结构件5.2，该结构件被插入固定在支撑结构3的框架39中。
图7表示具有高强度支撑结构的汽车驾驶室的例子。驾驶室由纵向高强度结构件5.1和平面件5.2连接而成，其中部分支撑结构和围绕的聚合物材料8可以构成车身部分。按这一方式也可以制造自支撑的塑料车身。
图2至7中所示的本发明的可能的应用当然只是例子，这些例子可以按某种方式和方法修改、变更或补充后。尤其是，所示的加强件或结构件5只被选择用来形成本发明的支撑结构3，以便详细说明本发明。当然，也可以不用管或杆而使用侧面型材、网或板条，如图2至7所述，也可使用别的加强件例如T-型材、U-型材、L型角板等等，作为平面结构件可以使用层压塑料、垫、蜂窝型结构等等。
所描述的应用例也只是为了说明本发明，当然，本发明的构思也可以用于制造任何必须满足载荷支撑作用的其他的壳体、容器、小室、集装箱、车身等等。
对于制造主要由一种聚合物材料制成的模制件和结构构件重要的是，首先构成支撑结构，接着，该支撑结构用构成模制件和结构构件的聚合物材料至少在部分范围包覆或浇注。其中，各形成支撑结构的结构件和最终形成模制件的聚合物材料可以是一层或多层，或者由多种组分组成。

Claims (24)

1．塑料模制件和结构构件，例如容器、壳体、储液罐、集装箱、管道、汽车驾驶室、车身，其特征在于，支撑结构(3)由多个相互连接的高强度、纤维加强的结构件(5)制成，这一支撑结构至少部分地被构成模制件的聚合物材料(8)所围住。
2．按照权利要求1的模制件，其特征在于，结构件(5)用由玻璃、碳、芳族聚酰胺、LC-聚合物制成的连续纤维或用其他的高强度聚合物纤维加强。
3．按照权利要求1或2中任一的模制件，其特征在于，作为基体材料的结构件(5)具有热塑性塑料，如聚酰胺、聚丙烯、聚乙烯对苯二酸盐、聚丁烯对苯二酸盐、聚碳酸酯、聚酰亚胺、聚丙烯酸酯、聚苯硫烯和聚醚醚酮。
4．按照权利要求1或2中任一的模制件，其特征在于，作为基体的结构件(5)具有一种热固性材料，例如聚亚胺酯、不饱和的聚酯树脂、环氧树脂、酚醛树脂、氨基塑料和酚醛清漆树脂。
5．按照上述任一权利要求的模制件，其特征在于，采用纵向结构如杆、管、棒、型材和平面结构如板条、层压塑料、范围结构、格子等等作为构成支撑结构(3)的结构件(5)。
6．按照上述任一权利要求的模制件，其特征在于，构成支撑结构(3)的结构件借助于连接件(7)相互连接。
7．按照上述任一权利要求的模制件，其特征在于，用于制造支撑结构的各结构件(5)用拉拔、挤压、连铸和其他的连续塑料加工法制造，其中，由连续材料制成的各结构件通过切割、冲裁、铣削、锯和接着的后加工制成。
8．按照上述任一权利要求的模制件，其特征在于，用于构成支撑结构的各结构件被制成多层，具有高强度的核心和作为最外层的连接层，它们与直接围住结构件的聚合物材料(8)是兼容的，因此，结构件和聚合物材料(8)通过连接层(9)牢固相互连接在一起。
9．按照上述任一权利要求的模制件，其特征在于，结构件(5)是兼容的，使得在与周围的聚合物材料(8)接触的接触面上发生扩散。
10．按照上述任一权利要求的模制件，其特征在于，聚合物材料(8)具有一种热塑性聚合物，如聚丙烯、聚乙烯对苯二酸盐、聚丁烯对苯二酸盐、聚碳酸酯、聚酰亚胺、聚丙烯酸酯、聚苯硫烯、聚醚醚酮。
11．按照上述任一权利要求的模制件，其特征在于，聚合物材料(8)具有短的和长的纤维加强。
12．按照上述任一权利要求的模制件，其特征在于，聚合物材料(8)构成在结构件(5)的连接点的连接区(6)。
13．按照上述任一权利要求的模制件，其特征在于，聚合物材料被设计成多层(8.1,8.2)并在各层中具有从结构件(5)至表面的减小的聚合物材料的强度和刚度。
14．按照上述任一权利要求的模制件，其特征在于，聚合物材料(8)至少部分被发泡(8.0)。
15．按照上述任一权利要求的模制件，其特征在于，聚合物材料(8)至少部分被着色。
16．制造按照权利要求1～15中任一所述的塑料模制件和结构构件的方法，其特征在于，包括下列步骤：
-采用由一种连续纤维加强的聚合物或一种高强度聚合物制成的结构件(5)；
-对所述的结构件进行切割、加工和裁剪；
-将结构件连接成支撑结构(3)；
-将至少一部分支撑结构放入一个浇铸模中；
-将热塑性聚合物熔液(8)注入模具中；
-对模制件脱模。
17．按照权利要求16的方法，其特征在于，通过注塑形成聚合物材料(8)。
18．按照权利要求16或17的方法，其特征在于，在脱模后，至少部分被包覆的支撑结构(3)被放入另一模具中，并在这一模具中注入另一种塑料聚合物熔液，用于形成多层的至少部分围住结构件的聚合物材料(8.1,8.2)。
19．按照权利要求16或17的方法，其特征在于，在注入塑性聚合物熔液后同一模具的容积接着通过可移动的壁加以扩大，接着在同一模具中注入另一种聚合物材料，以形成多层的围住结构件的聚合物材料。
20．按照权利要求16～19中任一的方法，其特征在于，多层结构件或聚合物材料可以通过在边界面上的粘附、边界面两侧的分子扩散、边界面上的化学反应、或通过在结构件(5)和聚合物材料(8)之间直接设置一粘附连接层(9)而在边界层上获得良好的粘附。
21．按照权利要求16的方法，其特征在于，用于形成支撑结构(3)的各连接件(5)通过形状连接的连接件(7)如可拧入的、可插入的和可卡入的连接件连接。
22．按照权利要求16的方法，其特征在于，各结构件(5)通过粘接、焊接等等相互连接。
23．按照权利要求16的方法，其特征在于，用于形成支撑结构的各结构件(5)的连接是通过借助于网、带等等来包覆各结构件而实现的。
24．汽车驾驶室，具有按照权利要求1～15的塑料模制件和结构构件。
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